Apparatus for securing stone and method of use

ABSTRACT

An apparatus and system for securing a body includes a bracket and a channel member connected to the bracket; wherein the channel member is configured to abut a surface contour of the body. The bracket is configured to attach to a surface. The channel member includes a first member connected to the bracket at a first angle; a second member attached to the first member at a second angle; and a third member attached to the second member at a third angle. A method of securing a body includes attaching first hanger to a surface, abutting a first portion of the body to a first channel member of the first hanger, abutting second portion of the body to a second portion of a second hanger, and attaching the second hanger to the surface.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Application No. 62/958,797, filed Jan. 9, 2020. This patent application is incorporated by reference herein in its entirety to provide continuity of disclosure.

FIELD OF THE INVENTION

The disclosed subject matter generally relates to structural hangers and more specifically to wall hangers for securing stone veneers.

BACKGROUND OF THE INVENTION

The use of masonry techniques have been used to attach manufactured stone veneers to a surface. The attachment surface is typically prepared through the use of an underlying fabric layer, a metal lathing, and a layer of mortar. Additional mortar is applied to a back side of the stone veneer before attaching the veneer to the prepared surface. After a section of veneer is installed to the surface, mortar may be used to fill the joints between the veneers depending on the desired aesthetics of the finished surface. The installation process is time intensive and requires extensive surface preparation.

The typical veneer system suffers due to the time required to specially prepare the attachment surface and attach each individual veneer to the surface using mortar. Additionally, the veneer system is susceptible to cracking and failure when exposed to additional loads or vibrations. It is desirable to efficiently attach stone veneers to a surface though mechanical means, such wall hangers, in order to increase the structural resiliency of the veneer system and reduce material costs and installation time.

SUMMARY

The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.

In embodiments of the disclosed subject matter, the unique apparatus, system, and methods described herein make use of an exemplary stone hanger design to improve the strength and resiliency of manufactured stone veneer system.

In embodiments of the disclosed subject matter, the application of the apparatus, system and methods of use described herein can extend far beyond the field of stone veneer systems. The apparatus, system and methods of use can be applied to any surface where it is desirable to attach natural or manufactured materials to a surface.

An apparatus for securing a body, such a stone veneer, is disclosed. The apparatus includes a bracket and a channel member connected to the bracket; wherein the channel member is configured to abut a surface contour of the body. The channel member includes a first member connected to the bracket at a first angle; a second member attached to the first member at a second angle; and a third member attached to the second member at a third angle. In some embodiments, the first and second angles are the same. In other embodiments the second and third angles are the same.

The bracket includes an aperture to assist in the attachment of the bracket to a surface. The bracket may further include a first and second planar body connected to each other, such as an L-bracket.

A system for securing a body, such a set of stone veneers, is disclosed. The system includes a set of bodies adjacent to a surface; each body of the set of bodies including a top body surface contour and a bottom body surface contour; and a set of hangers connected to the surface; wherein the set of hangers is configured to abut at least one of the top body surface contour and the bottom body surface contour; whereby the set of bodies is secured to the surface through abutment of the top surface body contour and the bottom body surface contour with the set of hangers. Each hanger of the set of hangers includes a bracket and a channel member connected to the bracket. The bracket includes and L-bracket and includes an aperture to assist in the attachment of the bracket to a surface. The channel member includes a set of planar surfaces configured to abut the top body surface contour and the bottom body surface contour.

The set of planar surfaces further includes a first member connected to the bracket at a first angle; a second member attached to the first member at a second angle; and a third member attached to the second member at a third angle. In some embodiments, the first and second angles are the same. In other embodiments the second and third angles are the same. The system further includes a set of securing hardware configured to attach the set of hangers to a surface. Mortar may be disposed between the set of bodies of the system.

A method for securing a body may include the steps providing a first hanger having a first channel member; providing a second hanger having a second channel member; attaching the first hanger to a surface; abutting a first portion of the body to the first channel member; abutting the second channel member to a second portion of the body; and attaching the second hanger to the surface; whereby the body is secured between the first channel member and the second channel member.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings constitute a part of this specification and include exemplary embodiments of the disclosed subject matter and illustrate various objects and features thereof.

FIG. 1 is an isometric view of the disclosed subject matter.

FIG. 2 is a side view of the disclosed subject matter.

FIG. 3 is a rear side view of the disclosed subject matter.

FIG. 4 is a front side view of the disclosed subject matter.

FIG. 5 is a top view of the disclosed subject matter.

FIG. 6 is a bottom view of the disclosed subject matter.

FIG. 7 is a side view of an embodiment of the disclosed subject matter.

FIG. 8 is a pictorial view of an embodiment of the disclosed subject matter.

FIG. 9 is a pictorial view of an embodiment of the disclosed subject matter.

FIG. 10 is a flow chart illustrating a method embodiment of the disclosed subject matter.

DETAILED DESCRIPTION

Detailed aspects of the disclosed subject matter are disclosed herein; however, it is to be understood that the disclosed aspects are merely exemplary of the disclosed subject matter, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art how to variously employ the disclosed technology in virtually any appropriately detailed structure.

The detailed description includes the disclosure of numerical ranges. Numerical ranges should be construed to provide literal support for claim limitations reciting only the upper value of a numerical range, and provide literal support for claim limitations reciting only the lower value of a numerical range.

It is to be understood that while certain aspects of the disclosed subject matter have been shown and described, the disclosed subject matter is not limited thereto and encompasses various other embodiments and aspects.

The disclosed subject matter will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present disclosed subject matter, proportional relationships of the elements have not been maintained in the figures. In some cases, the sizes of certain small components have been exaggerated for illustration.

Referring to FIGS. 1-6, in an embodiment of the disclosed subject matter, an apparatus 100 for securing a body includes a bracket 102 and a channel member 104 connected to the bracket 102. The channel member 104 includes a first member 106 connected to the bracket 102 at a first angle α₁; a second member 108 attached to the first member 106 at a second angle α₂; and a third member 110 attached to the second member 108 at a third angle α₃. In some embodiments, the second angle α₂ and the third angle α₃ are the same. In other embodiments, the second angle α₂ and the third angle α₃ are preferably obtuse, at least 110° and no more than 115°; and most preferably about 112°. Other suitable angles may be employed.

The bracket 102 includes a first planar body 112 connected to a second planar body 114. The planar bodies (112, 114) are connected at a predetermined angle α₄. In an embodiment of the disclosed subject matter, the predetermined angle α₄ is a right angle (90°). The bracket 102 includes an L-bracket or other suitable configuration for attachment to a surface. In other embodiments, the second angle α₂ is configured so the second member 108 is perpendicular to the first planar body 112. Other suitable angles and arrangements may be employed.

In some embodiments, the bracket 102 includes an aperture 116 disposed through the first planar body 112. The aperture 116 is configured to accept a securing hardware (not shown) such as a bolt, screw, nail, or other suitable hardware in order to attach the first planar body 112 to a surface (not shown). In an embodiment of the disclosed subject matter, the diameter of aperture 116 is preferably at least 0.1 inches and no more than 0.2 inches; and most preferably about 0.188 inches. Other suitable dimensions may be employed. The aperture 116 is preferably centrally disposed on the first planar body 112 and preferably disposed above a second top surface 124 of the second member 108 in order to assist in accessing the aperture 116 with an attachment tool such a hammer, screwdriver, nail gun, or other suitable tool used in connection with the securing hardware. Other suitable locations of aperture 116 may be employed.

In an embodiment of the disclosed subject matter, the second planar body 114 and second member 108 are in parallel arrangement so that the first angle α₁ and the second angle α₂ are about the same. In an embodiment, the first angle α₁ and the second angle α₂ are preferably obtuse, at least 110° and no more than 115°; and most preferably about 112°. Other suitable arrangements and angles may be employed.

Referring to FIG. 2, the first member 106 includes a first top surface 120 and a first bottom surface 122 disposed opposite and parallel to the first top surface 120. The second member 108 includes a second top surface 124 and a second bottom surface 126 disposed opposite and parallel to the second top surface 124. The third member 110 includes a third top surface 128 and a third bottom surface 130 disposed opposite and parallel to the third top surface.

The apparatus 100 is preferably constructed as a single unit comprising the same material throughout. For example, in some embodiments, the apparatus may be constructed entirely of plastic, metal, steel, or fiberglass. Alternatively, portions of the apparatus such as the bracket 102 and channel member 104 may be constructed of different materials and joined together using suitable means of connection such as welds, clamps, bolts, or adhesives. Other suitable materials known in the art may be employed.

Referring to FIG. 7, a body 200 includes a top body surface contour 202 and a bottom body surface contour 204; wherein the top body surface contour 202 is configured to abut a first, second, and third bottom surfaces (122, 126, 130) of apparatus 100 a; and wherein the bottom body surface contour 204 is configured to abut a first, second, and third top surfaces (120, 124, 128) of apparatus 100 b. The top and bottom body surface contours (202, 204) is preferably precast into the body 200 to form a unitary construction. In an embodiment of the disclosed subject matter the body 200 is a stone veneer for attachment to a wall surface 300. The top body surface contour 202 includes the general shape of a tongue 206 so as to abut the bottom surfaces (122, 126, 130). The bottom body surface contour 204 includes a general shape of a groove 208 so as to abut the top surfaces (120, 124, 128).

In one embodiment, the body 100 is secured to a surface 300 by abutting a first apparatus 100 a to the top body surface contour 202 and a second apparatus 100 b the bottom body surface contour 204. The body 200 is therefore secured between the first apparatus 100 a and the second apparatus 100 b when the first and second apparatus (100 a, 100 b) are attached to the surface 300 with a set of securing hardware 302. A set of bodies 200 a, 200 b is secured to the surface 300 either above or below the pair of apparatus 100 a, 100 b in a similar manner as body 200 as previously described.

A system for securing a body includes a set of bodies 700 (illustrated as bodies 200, 200 a, 200 b) adjacent to a surface 300; wherein each body of the set of bodies 700 including a top body surface contour 202 and a bottom body surface contour 204; and a set of hangers (702 a, 702 b) connected to the surface by at least one of a set of securing hardware 302; wherein the set of hangers (702 a, 702 b) is configured to abut at least one of the top body surface contour 202 and the bottom body surface contour 204; whereby the set of bodies 700 is secured to the surface 300 through abutment of the top surface body contour 202 and the bottom body surface contour 204 with the set of hangers (702 a, 702 b). Each hanger of the set of hangers (702 a, 702 b) includes similar features as the apparatus 100 previously discussed and illustrated in FIGS. 1-6.

Referring to FIG. 8, in an embodiment of the disclosed subject matter, a set of hangers 800 a-i may be configured along a set of horizontal lines (802 a-c) to achieve a linear appearance of a set of bodies 804 a-f disposed between the set of hangers. In this configuration, a linear pattern of bodies is achieved. In some embodiments, the set of bodies is horizontally offset between alternating horizontal lines (802 a-c) such that the vertical lines do not line up. If the set of bodies 804 a-f includes stone veneers, the appearance of a linear stone pattern is then achieved.

Referring to FIG. 9, in another embodiment of the disclosed subject matter, a set of hangers 900 is disposed at varying positions upon the wall surface 300. The position of the set of hangers 900 depend on the geometry of the set of bodies 902, wherein at least one hanger of the set of hangers 900 abuts a top edge 904 and a bottom edge 906 of each body of the set of bodies 902. In one embodiment, the set of bodies 900 includes a set of stone veneers in order to achieve the appearance of random stone surface adjacent to the wall surface 300.

In some embodiments, and referring to flow chart 1000 of FIG. 10, a method for securing a body includes, at step 1002, providing a first hanger having a first channel member, and providing a second hanger having a second channel member. The method further includes, at step 1004, attaching the first hanger to a surface. The method further includes, at step 1006, abutting a first portion of the body to the first channel member. The method further includes, at step 1008, abutting the second channel member to a second portion of the body. The method further includes, at step 1010, attaching the second hanger to the surface; whereby the body is secured between the first channel member and the second channel member. In some embodiments, the method further includes, at step 1012, applying a mortar mixture to a peripheral edge of the body.

In an embodiment of the method illustrated in flow chart 1000, the first portion includes a first surface contour configured to abut the first channel member. In some embodiments of the disclosed subject matter, the first surface contour includes a groove configured to engage the first channel member. The second portion includes a second surface contour configured to abut the second channel member. In some embodiments of the disclosed subject matter, the second surface contour includes a tongue configured to engage the second channel member.

Although the invention has been disclosed with reference to various particular embodiments, it is understood that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims.

It is to be understood that while certain aspects of the disclosed subject matter have been shown and described, the disclosed subject matter is not limited thereto and encompasses various other embodiments and aspects. 

1. An apparatus for securing a body comprising: a bracket; a channel member connected to the bracket, comprising: a first member connected to the bracket at a first angle; a second member attached to the first member at a second angle; and, a third member attached to the second member at a third angle.
 2. The apparatus of claim 1, wherein the channel member is configured to abut a surface contour of the body.
 3. The apparatus of claim 1, wherein the second angle and the third angle are the same.
 4. The apparatus of claim 1, wherein the bracket comprises: a first planar body configured to connect to a structure; and a second planar body connected to the first planar body.
 5. The apparatus of claim 4, wherein the first planar body and the second planar body are connected at a right angle.
 6. The apparatus of claim 4, wherein the first planar body comprises an aperture.
 7. The apparatus of claim 1, wherein the first angle and the second angle are the same.
 8. A system for securing a body comprising: a surface; a set of bodies adjacent to the surface; each body of the set of bodies comprising a top body surface contour and a bottom body surface contour; a set of hangers connected to the surface; wherein the set of hangers is configured to abut at least one of the top body surface contour and the bottom body surface contour; and whereby the set of bodies is secured to the surface through abutment of the top surface body contour and the bottom body surface contour with the set of hangers.
 9. The system for securing a body of claim 8, wherein each hanger of the set of hangers comprises: a bracket; and a channel member connected to the bracket.
 10. The system for securing a body of claim 9, wherein the channel member comprises a set of planar surfaces configured to abut the top body surface contour and the bottom body surface contour.
 11. The system for securing a body of claim 10, wherein the set of planar surfaces comprises: a first member connected to the bracket at a first angle; a second member attached to the first member at a second angle; and, a third member attached to the second member at a third angle.
 12. The system for securing a body of claim 11, wherein the second angle and the third angle are the same.
 13. The system for securing a body of claim 11, wherein the first angle and the second angle are the same.
 14. The system for securing a body of claim 9, wherein the channel bracket is an L-bracket.
 15. The system for securing a body of claim 9, wherein the bracket comprises an aperture.
 16. The system for securing a body of claim 8, further comprising a set of securing hardware configured to attach the set of hangers to the surface.
 17. The system for securing a body of claim 8, further comprising a mortar disposed between the set of bodies.
 18. A method for securing a body, comprising the steps of: providing a first hanger having a first channel member; providing a second hanger having a second channel member; attaching the first hanger to a surface; abutting a first portion of the body to the first channel member; abutting the second channel member to a second portion of the body; and, attaching the second hanger to the surface; whereby the body is secured between the first channel member and the second channel member.
 19. The method of claim 18, wherein the first portion comprises a first surface contour configured to abut the first channel member; and wherein the second portion comprises a second surface contour configured to abut the second channel member.
 20. The method of claim 19, wherein the first surface contour comprises a groove; and wherein the second surface contour comprises a tongue.
 21. The method of claim 18, further comprising the step of applying a mortar mixture to a peripheral edge of the body. 